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Old 04-19-2015, 03:32 PM
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Access panel over gas tank?

Has anyone ever cut an access panel in the tub of their jeep above the gas tank in order to fix their fuel pump before? I have dropped my tank about 4 times now it's not to much of a pain in the ass but I was wondering if it's just smarter if I were to cut a hole in the tub above the tank and then made it removable. Seal it up possibly with some flashing tape used for windows. Any thoughts? Any drawbacks anyone can think of?

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Old 04-19-2015, 03:39 PM   #2
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That is a common thing for people to do on their XJ. I don't see why it would be an issue. The only thing I could see that would be an issue are those ribs in the back so they plate wouldn't sit flush unless you addressed that

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Old 04-19-2015, 05:03 PM   #3
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I have a 91. The PO cut an access panel above the gas tank. I didn't even know it was there until I ripped the carpet out. Where it is located you never really see it. It is about a five minute job to pull and replace the pump. I recommend.
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Old 09-22-2015, 07:58 PM   #4
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I'm about to do this,,, how worried should I be about the Sparks that it'll create directly over the gas tank?
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Old 09-23-2015, 07:37 AM   #5
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Originally Posted by beardown View Post
I'm about to do this,,, how worried should I be about the Sparks that it'll create directly over the gas tank?
Not to be a smartass, but how leaky is your tank/are your lines?

You should be as proportionally-worried as is the likelihood of leaks.

Be save, wear googles, FILL the tank (less vapor) or better yet--DROP the tank, first.
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Old 09-23-2015, 08:39 AM   #6
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I've done this mod before. I needed to replace my fuel level seder unit. My advice is just take your time with the measurements. Trace everything out.
like the others have said, wear gloves and safety glasses.
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Old 09-23-2015, 08:54 AM   #7
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Would running a hose under there be smart? Or pointless? And, how much room is there between the floor and the tank?
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Old 09-23-2015, 09:10 AM   #8
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I'd drop the tank and do it right the first time.
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Old 09-23-2015, 12:29 PM   #9
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Dropping the tank would be the smartest route.

Getting things wet under there before you start cutting would be the second best, or putting some damp rags over the top of the tank, but without a body lift, that is next to impossible.

I did this on a customers YJ. I used a 4.5" grinder with a cut-off wheel to do the cuts. I put the nose of the grinder on a board that was thick enough so that the cut-off wheel was just barely cutting into the floor. You have a little over an inch of room on the passenger side of the hole to be cut, but on the driver's side (because of the hoses and wires) There is less than 1/2". Hence the board limiting the depth of the cut-off wheel.

I don't have the dimensions anymore or the actual hole size. I cut like 4 different times in order to make it big enough to work in there. Sealing it up again was another story all together. I had to build a base that sat in all the ribs to make a good seal then a flat plate to top it off.
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Old 09-23-2015, 02:37 PM   #10
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Read the responses to beardowns post. More help on the same topic.
Good Luck, L.M.
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Old 09-23-2015, 02:58 PM   #11
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Considering if there is a leak your jeep could burn to the ground in minutes and it only takes an hour to drop the gas tank. I would go the safe route!

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